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注塑制品开裂的原因分析
注塑制品开裂，包括制件表面丝状裂纹、微裂、顶白、开裂及因制件粘模、流道粘模而造成或创伤危机，按开裂时间分脱模开裂和应用开裂。主要有以下几个方面的原因造成：
1．加工方面：
（1）加工压力过大、速度过快、充料愈多、注射、保压时间过长，都会造成内应力过大而开裂。
（2）调节开模速度与压力防止快速强拉制件造成脱模开裂。
（3）适当调高模具温度，使制件易于脱模，适当调低料温防止分解。
（4）预防由于熔接痕，塑料降解造成机械强度变低而出现开裂。
（5）适当使用脱模剂，注意经常消除模面附着的气雾等物质。
（6）制件残余应力，可通过在成型后立即进行退火热处理来消除内应力而减少裂纹的生成。
2．模具方面:
（1）顶出要平衡，如顶杆数量、截面积要足够，脱模斜度要足够，型腔面要有足够光滑，这样才防止由于外力导致顶出残余应力
集中而开裂。
（2）制件结构不能太薄，过渡部份应尽量采用圆弧过渡，避免尖角、倒角造成应力集中。
（3）尽量少用金属嵌件，以防止嵌件与制件收缩率不同造成内应力加大。
（4）对深底制件应设置适当的脱模进气孔道，防止形成真空负压。
（5）主流道足够大使浇口料未来得及固化时脱模，这样易于脱模。
（6）主流道衬套与喷嘴接合应当防止冷硬料的拖拉而使制件粘在定模上。
3．材料方面：
（1）再生料含量太高，造成制件强度过低。
（2）湿度过大，造成一些塑料与水汽发生化学反应，降低强度而出现顶出开裂。
（3）材料本身不适宜正在加工的环境或质量欠佳，受到污染都会造成开裂。
4．机台方面：
注塑机塑化容量要适当，过小塑化不充分未能完全混合而变脆，过大时会降解。
部分型号部分物性表
PP (polypropylene # folding glue | soft French Total /MR2001/)
Use: fiber grade
Characteristic notes: high flow, bllocene polymer
Important beters: melt flow rate: 25 g/10min density: 0.905 g/cm3 flexural modulus: 1300 MPa
Manufacturer: Total Petrochemical Industries Co
PP (polypropylene # folding glue | soft French Total /MR2002/)
Use: fiber grade
Characteristic notes: bllocene polymer, high flow
Important beters: melt flow rate: 15 g/10min density: 0.905 g/cm3 flexural modulus: 1300 MPa
Manufacturer: Total Petrochemical Industries Co
PP (polypropylene # folding glue | soft /5D39/ DuPont Dow)
Use: film grade
Important beters: melt flow rate: 2.7 g/10min density: 0.9 g/cm3, notched impact strength: 35 tensile strength: 31.7 MPa, elongation at break: 9% bending modulus: 1310 MPa, hot debation temperature: 104 degrees.
Manufacturer: Dow DuPont Co
PP (polypropylene # folding glue | soft /SRD5-1592/ DuPont Dow)
Use: film grade
Important beters: melt flow rate: 2.8 g/10min density: 0.9 g/cm3, notched impact strength: 34.7 tensile strength: 32 MPa, elongation at break: 9% bending modulus: 1310 MPa, hot debation temperature: 104 degrees.
Manufacturer: Dow DuPont Co
PP (polypropylene # folding glue | soft /3674F3/ Mobil Exxon)
Use: other
Important beters: melt flow rate: 22 g/10min notch impact strength: 2.6 fracture elongation: 9% flexural modulus: 1400 MPa hardness: 68 VEKA softening point: 156 C
Manufacturer: Exxon Mobil Corp
PP (polypropylene # folding glue | soft /7043L1/ Mobil Exxon)
Use: other
Important beters: melt flow rate: 8 g/10min density: 0.9 g/cm3, notched impact strength: 10 bending modulus: 1050 MPa VEKA softening point: 146 DEG heat debing temperature: 49 C.
Manufacturer: Exxon Mobil Corp
PP (polypropylene # folding glue | soft /PPH106/ Pulilang)
Use: other
Important beters: melt flow rate: 6 g/10min density: 0.93 g/cm3, molding shrinkage: 1.5% notched impact strength: 50 tensile strength: 35 MPa, elongation at break: 80% bending strength: 45 MPa bending modulus: 1500 MPa hardness: 95 thermal debing temperature: 68 degrees.
Manufacturer: Pulilang Industrial Co. Ltd.
PP (polypropylene # folding glue | soft) /V6065/ RAVAGO of Belgium
Use: other
Characteristic notes: injection molding
Important beters: notch impact strength: 40 tensile strength: 100 MPa breaking elongation: 1.2% bending strength: 210 MPa flexural modulus: 13000 MPa
Manufacturer: RAVAGO group, Belgium
PP (polypropylene # folding glue | soft) /34-1520 TFPP/ 2007.pdf
Use: other
Characteristic notes: characteristic medium flow
Important beters: density: 1.05 g/cm3, molding shrinkage: 1%, tensile strength: 33.8 MPa, elongation at break: 45% flexural strength: 50.5 MPa, bending modulus: 2170 MPa, hot debation temperature: 124 degrees.
Manufacturer: United States PolyOne Corporation
PP (polypropylene # folding glue | soft) /NT818.G002-1000/ 2007.pdf
Use: other
Important beters: density: 1.1 g/cm3 tensile strength: 68.9 MPa breaking elongation: 5% bending strength: 100 MPa flexural modulus: 4620 MPa thermal debation temperature: 160 C
Manufacturer: United States PolyOne Corporation
PP (polypropylene # folding glue | soft) /NT-818.G002-8000/ 2007.pdf
Use: other
Important beters: density: 1.1 g/cm3 tensile strength: 68.9 MPa breaking elongation: 5% bending strength: 100 MPa flexural modulus: 4620 MPa thermal debation temperature: 160 C
Manufacturer: United States PolyOne Corporation
PP (polypropylene # folding glue | soft plastic /3475-01/ Schulman)
Use: other
Characteristic notes: high melt, homopolymer
Important beters: melt flow rate: 90 g/10min density: 0.9 g/cm3 notch impact strength: 0.4 tensile strength: 29 MPa breaking elongation: 5% flexural modulus: 1300 MPa
Manufacturer: Schulman plastics company
PP (polypropylene # folding glue | soft /PPC 5660/ France Total)
Use: other
Characteristic notes: medium flow
Important beters: melt flow rate: 7 g/10min density: 0.905 g/cm3, notched impact strength: 10 tensile strength: 25 MPa, elongation at break: 6% bending modulus: 1200 MPa hardness: 85 VEKA softening point: 65 DEG heat debing temperature: 50 C.
Manufacturer: Total Petrochemical Industries Co
PP (polypropylene # folding glue | soft /E310G/ Asahi Kasei)
Use: other
Important beters: melt flow rate: 0.5 g/10min
Manufacturer: Japan Asahi Chemical Industry Corporation
PP (polypropylene # folding glue | soft /E420G/ Asahi Kasei)
Use: other
Important beters: melt flow rate: 1.5 g/10min
Manufacturer: Japan Asahi Chemical Industry Corporation
PP (polypropylene # folding glue | soft /1148TC/ Oman petrochemical)
Use: other
Characteristic notes: antistatic, homopolymer
Important beters: melt flow rate: 53 g/10min density: 0.91 g/cm3, notched impact strength: 0.3 tensile strength: 36 MPa, elongation at break: 50% bending modulus: 1462 MPa, hot debation temperature: 104 degrees.
Manufacturer: Oman Petrochemical Industries Co
PP (polypropylene # folding glue | soft) /EPC31HR/ Lanzhou petrochemical
Use: other
Characteristic notes: high impact and high rigidity
Important beters: melt flow rate: 6 g/10min tensile strength: 26 MPa VEKA softening point: 152 C
Manufacturer: PetroChina Lanzhou Petrochemical Branch
PP (polypropylene # folding glue | soft /F120K/ Asahi Kasei)
Use: film grade
Important beters: melt flow rate: 1.5 g/10min
Manufacturer: Japan Asahi Chemical Industry Corporation
PP (polypropylene # folding glue | soft /S6730/ Asahi Kasei)
Use: other
Characteristic notes: polyolefin composite resin, high specific gravity compound
Important beters: melt flow rate: 4 g/10min
Manufacturer: Japan Asahi Chemical Industry Corporation
PP (polypropylene # folding glue | soft plastic /1120/ Taiwan)
Use: other
Feature notes: FDA certification
